Contoured fluid-filled chamber with tensile structures

ABSTRACT

A fluid-filled chamber, which may be incorporated into articles of footwear and other products, may include an outer barrier, a first tensile structure, and a second tensile structure. Any of the first and second tensile structures may include one or more textile tensile members. The first and second tensile structures may be located within an interior void defined by the outer barrier and may be bonded to the outer barrier. The first and second tensile structures may be bonded to the outer barrier in different areas of the outer barrier that are in fluid communication with each other. The first tensile structure may have a height greater than a height of the second tensile structure. In turn, the relative locations and differences of height between the tensile structures may impart a contour to the chamber.

CROSS REFERENCE TO RELATED APPLICATIONS

This non-provisional U.S. Patent Application is a continuation andclaims priority to U.S. patent application Ser. No. 14/305,752, whichwas filed in the U.S. Patent and Trademark Office on Jun. 16, 2014,which is a continuation and claims priority to U.S. patent applicationSer. No. 13/049,268, which was filed in the U.S. Patent and TrademarkOffice on Mar. 16, 2011, the contents of which are hereby incorporatedby reference in their entirety.

BACKGROUND

Articles of footwear generally include two primary elements, an upperand a sole structure. The upper is formed from a variety of materialelements (e.g., textiles, foam, leather, and synthetic leather) that arestitched or adhesively bonded together to form a void on the interior ofthe footwear for comfortably and securely receiving a foot. An ankleopening through the material elements provides access to the void,thereby facilitating entry and removal of the foot from the void. Inaddition, a lace is utilized to modify the dimensions of the void andsecure the foot within the void.

The sole structure is located adjacent to a lower portion of the upperand is generally positioned between the foot and the ground. In manyarticles of footwear, including athletic footwear, the sole structureconventionally incorporates an insole, a midsole, and an outsole. Theinsole is a thin compressible member located within the void andadjacent to a lower surface of the void to enhance footwear comfort. Themidsole, which may be secured to a lower surface of the upper andextends downward from the upper, forms a middle layer of the solestructure. In addition to attenuating ground reaction forces (i.e.,providing cushioning for the foot), the midsole may limit foot motionsor impart stability, for example. The outsole, which may be secured to alower surface of the midsole, forms the ground-contacting portion of thefootwear and is usually fashioned from a durable and wear-resistantmaterial that includes texturing to improve traction.

The conventional midsole is primarily formed from a foamed polymermaterial, such as polyurethane or ethylvinylacetate, that extendsthroughout a length and width of the footwear. In some articles offootwear, the midsole may incorporate a variety of additional footwearelements that enhance the comfort or performance of the footwear,including plates, moderators, fluid-filled chambers, lasting elements,or motion control members. In some configurations, any of theseadditional footwear elements may be located between the midsole and theupper or between the midsole and the outsole, may be embedded within themidsole, or may be encapsulated by the foamed polymer material of themidsole, for example. Although many conventional midsoles are primarilyformed from a foamed polymer material, fluid-filled chambers or othernon-foam structures may form part of or a majority of some midsoleconfigurations.

SUMMARY

Various features of a fluid-filled chamber, which may be incorporatedinto articles of footwear and other products, are disclosed below. Inone configuration, a fluid-filled chamber comprises an outer barrier, afirst tensile structure, and a second tensile structure. The outerbarrier defines an interior void and has a first area and a second area,the first area and second area being in fluid communication. The firsttensile structure is located within the interior void, is bonded to theouter barrier in the first area, and has a first height. The secondtensile structure is located within the interior void, is bonded to theouter barrier in the second area, and has a second height. The firstheight is greater than the second height.

In another configuration, an article of footwear incorporates a solestructure, the sole structure comprising a midsole and an outsole. Themidsole includes a fluid-filled chamber. The fluid-filled chambercomprises an outer barrier, a first tensile structure, and a secondtensile structure. The outer barrier has an upper portion, an oppositelower portion, and a peripheral edge. The first tensile structure islocated within the outer barrier. The second tensile structure islocated within the outer barrier. The outsole is secured to the midsoleand forms at least part of a ground-contacting surface of the footwear.The first tensile structure has a first height at a first part near thesecond tensile structure, and the second tensile structure has a secondheight greater than the first height at a second part near the firsttensile structure. An area of the chamber located between the first partand the second part is substantially free of interior bonds.

In a further configuration, an article of footwear incorporates a solestructure, the sole structure comprising a midsole and an outsole. Themidsole includes a fluid-filled chamber. The fluid-filled chambercomprises an outer barrier, a first tensile structure, and a secondtensile structure. The first tensile structure is located within theouter barrier in a first area of the chamber and has a first height. Thesecond tensile structure is located within the outer barrier in a secondarea of the chamber, the second area being in fluid communication withthe first area, and has a second height greater than the first height.The outsole is secured to the midsole and forms at least part of aground-contacting surface of the footwear. The second tensile structureis located in at least a heel region of the footwear, and the firsttensile structure is located rearward of the second tensile structure.

In another further configuration, an article of footwear incorporates asole structure, the sole structure comprising a midsole and an outsole.The midsole includes a fluid-filled chamber. The fluid-filled chambercomprises an outer barrier, a first tensile structure, and a secondtensile structure. The outer barrier has an upper portion, an oppositelower portion, and a peripheral edge. The first tensile structure islocated within the outer barrier in a first area of the chamber and hasa first height. The second tensile structure is located within the outerbarrier in a second area of the chamber, the second area being in fluidcommunication with the first area, and has a second height less than thefirst height. The outsole is secured to the midsole and forms at leastpart of a ground-contacting surface of the footwear. The first tensilestructure is located in at least a midfoot region of the footwear, andthe second tensile structure is located forward of the first tensilestructure.

In still another further configuration, an article of footwearincorporates a sole structure, the sole structure comprising a midsoleand an outsole. The midsole includes a fluid-filled chamber. Thefluid-filled chamber comprises an outer barrier, a first tensilestructure, a second tensile structure, and a third tensile structure.The outer barrier has an upper portion, an opposite lower portion, and aperipheral edge. The first tensile structure is located within the outerbarrier in a first area of the chamber. The second tensile structure islocated within the outer barrier in a second area of the chamber. Thethird tensile structure is located within the outer barrier in a thirdarea of the chamber. The outsole is secured to the midsole and forms atleast part of a ground-contacting surface of the footwear. The firstarea is in a rear-most region of the chamber and has a first height. Thesecond area of the chamber is between the rear-most region of thechamber and a fore-most region of the chamber and has a second heightgreater than the first height. The third area of the chamber is in afore-most region of the chamber and has a third height less than thesecond height.

The advantages and features of novelty characterizing aspects of theinvention are pointed out with particularity in the appended claims. Togain an improved understanding of the advantages and features ofnovelty, however, reference may be made to the following descriptivematter and accompanying figures that describe and illustrate variousconfigurations and concepts related to the invention.

FIGURE DESCRIPTIONS

The foregoing Summary and the following Detailed Description will bebetter understood when read in conjunction with the accompanyingfigures.

FIG. 1 is a lateral side elevational view of an article of footwearincorporating a fluid-filled chamber.

FIG. 2 is a cross-sectional view of the article of footwear, as definedby section line 2-2 in FIG. 1.

FIGS. 3A-3B are cross-sectional views corresponding with FIG. 2 anddepicting additional configurations of the article of footwear.

FIG. 4 is a perspective view of the chamber.

FIG. 5 is an exploded perspective view of the chamber.

FIG. 6 is a top plan view of the chamber.

FIG. 7 is a lateral side elevational view of the chamber.

FIGS. 8A-8D are cross-sectional views of the chamber, as defined bysection lines 8A-8A through 8D-8D in FIG. 6.

FIG. 9 is a perspective view of a mold that may be utilized for aprocess for manufacturing the chamber.

FIGS. 10A-10E are side elevational views of the mold depicting steps inthe process for manufacturing the chamber.

FIGS. 11A-11E are schematic cross-sectional views of the mold, asdefined by section lines 11A-11A through 11E-11E in FIGS. 10A-10E,depicting steps in the process for manufacturing the chamber.

FIGS. 12A-12H are top plan views corresponding with FIG. 6 and depictingadditional configurations of the chamber.

FIGS. 13A-13E are cross-sectional views corresponding with FIG. 8D anddepicting additional configurations of the chamber.

FIG. 14 is a cross-sectional view corresponding with FIG. 8C anddepicting an additional configuration of the chamber.

FIG. 15 is a cross-sectional view corresponding with FIG. 8B anddepicting an additional configuration of the chamber.

FIGS. 16A-16B are perspective views of other articles incorporatingfluid-filled chambers.

FIG. 17 is a top plan view of an alternate configuration of afluid-filled chamber.

FIG. 18 is a medial side elevational view of the alternate configurationof the chamber.

DETAILED DESCRIPTION

The following discussion and accompanying figures disclose variousconfigurations of fluid-filled chambers and methods for manufacturingthe chambers. Although the chambers are disclosed with reference tofootwear having a configuration that is suitable for running, conceptsassociated with the chambers may be applied to a wide range of athleticfootwear styles, including basketball shoes, cross-training shoes,football shoes, golf shoes, hiking shoes and boots, ski and snowboardingboots, soccer shoes, tennis shoes, and walking shoes, for example.Concepts associated with the chambers may also be utilized with footwearstyles that are generally considered to be non-athletic, including dressshoes, loafers, and sandals. In addition to footwear, the chambers maybe incorporated into other types of apparel and athletic equipment,including helmets, gloves, and protective padding for sports such asfootball and hockey. Similar chambers may also be incorporated intocushions and other compressible structures utilized in household goodsand industrial products. Accordingly, chambers incorporating theconcepts disclosed herein may be utilized with a variety of products.

General Footwear Structure

An article of footwear 10 is depicted in FIGS. 1-3B as including anupper 20 and a sole structure 30. For reference purposes, footwear 10may be divided into three general regions: a forefoot region 11, amidfoot region 12, and a heel region 13, as shown in FIG. 1. Forefootregion 11 generally includes portions of footwear 10 corresponding withthe toes and the joints connecting the metatarsals with the phalanges.Midfoot region 12 generally includes portions of footwear 10corresponding with the arch area of the foot. Heel region 13 generallyincludes portions of footwear 10 corresponding with rear portions of thefoot, including the calcaneus bone. Regions 11-13 are not intended todemarcate precise areas of footwear 10. Rather, regions 11-13 areintended to represent general areas of footwear 10 to aid in thefollowing discussion. In addition to being applied to footwear 10,regions 11-13 may also be applied to upper 20, sole structure 30, andindividual elements thereof. Footwear 10 also includes a lateral side 14and a medial side 15, as shown in FIGS. 2-3B. Lateral side 14 and medialside 15 also extend through each of regions 11-13 and correspond withopposite sides of footwear 10. As with regions 11-13, sides 14 and 15represent general areas of footwear 10 to aid in the followingdiscussion, and may also be applied to upper 20, sole structure 30, andindividual elements thereof in addition to being applied to footwear 10.

Upper 20 is depicted as having a substantially conventionalconfiguration incorporating a plurality of material elements (e.g.,textile, foam, leather, and synthetic leather) that are stitched,adhered, bonded, or otherwise joined together to form an interior voidfor securely and comfortably receiving a foot. The material elements maybe selected and located with respect to upper 20 in order to selectivelyimpart properties of durability, air-permeability, wear-resistance,flexibility, and comfort, for example. An ankle opening 21 in heelregion 13 provides access to the interior void. In addition, upper 20may include a lace 22 that is utilized in a conventional manner tomodify the dimensions of the interior void, thereby securing the footwithin the interior void and facilitating entry and removal of the footfrom the interior void. Lace 22 may extend through apertures in upper20, and a tongue portion of upper 20 may extend between the interiorvoid and lace 22. Upper 20 may also incorporate a sockliner 23 that islocated within the void in upper 20 and adjacent a plantar (i.e., lower)surface of the foot to enhance the comfort of footwear 10. Given thatvarious aspects of the present application primarily relate to solestructure 30, upper 20 may exhibit the general configuration discussedabove or the general configuration of practically any other conventionalor non-conventional upper. Accordingly, the overall structure of upper20 may vary significantly.

Sole structure 30 is secured to upper 20 and has a configuration thatextends between upper 20 and the ground. In effect, therefore, solestructure 30 is located to extend between the foot and the ground. Inaddition to attenuating ground reaction forces (i.e., providingcushioning for the foot), sole structure 30 may provide traction, impartstability, and limit various foot motions, such as pronation. Theprimary elements of sole structure 30 are a midsole 31 and an outsole32. Midsole 31 may incorporate a polymer foam material, such aspolyurethane or ethylvinylacetate. Midsole 31 may also incorporate afluid-filled chamber 33. In addition to the polymer foam material andchamber 33, midsole 31 may incorporate one or more other footwearelements that enhance the comfort, performance, or ground reaction forceattenuation properties of footwear 10, including plates, moderators,lasting elements, or motion control members.

Outsole 32, which may be absent in some configurations of footwear 10,is secured to a lower surface of midsole 31 and forms at least part of aground-contacting surface of footwear 10. Outsole 32 may be formed froma rubber material that provides a durable and wear-resistant surface forengaging the ground. In addition, outsole 32 may also be textured toenhance the traction (i.e., friction) properties between footwear 10 andthe ground. In further configurations, and depending upon the manner inwhich midsole 31 incorporates the polymer foam material, chamber 33, orboth, outsole 32 may be secured to the polymer foam material alone, tochamber 33 alone, or to both the polymer foam material and chamber 33.

As incorporated into footwear 10, chamber 33 has a shape that extendsthrough substantially all of footwear 10, from forefoot region 11 toheel region 13 and also from lateral side 14 to medial side 15, therebyhaving a shape that corresponds with an outline of the foot and extendsunder substantially all of the foot. Accordingly, when the foot islocated within upper 20, chamber 33 extends under the foot in order toattenuate ground reaction forces that are generated when sole structure30 is compressed between the foot and the ground during variousambulatory activities, such as running and walking. In otherconfigurations, chamber 33 may extend through less than all of footwear10. For example, chamber 33 may extend only through forefoot region 11,or only through midfoot region 12, or only through heel region 13.Alternatively, chamber 33 may extend only through lateral side 14 offootwear 10, or only through medial side 15 of footwear 10. Chamber 33may also extend through any combination of regions and sides. That is,in various configurations, chamber 33 may extend through any portion offootwear 10.

As depicted in FIGS. 1-3B, chamber 33 is positioned below a polymer foammaterial of midsole 31 and is secured to the polymer foam material aswell as to outsole 32. In some configurations, however, chamber 33 maybe above a polymer foam material of midsole 31, between layers of apolymer foam material of midsole 31, at least partially encapsulated bya polymer foam material of midsole 31, or even substantially surroundedby or entirely encapsulated within a polymer foam material of midsole31, as depicted in FIG. 3A. In other configurations, chamber 33 may besecured to a plate 23 or other structure within midsole 31. In furtherconfigurations, the polymer foam material of midsole 31 may be absentand chamber 33 may be secured to both upper 20 and outsole 32.Accordingly, the overall shape of chamber 33 and the manner in whichchamber 33 is incorporated into footwear 10 may vary significantly.

Although chamber 33 is depicted and discussed as being a sealed chamberwithin footwear 10, chamber 33 may also be a component of a fluid systemwithin footwear 10. More particularly, pumps, conduits, and valves maybe joined with chamber 33 to provide a fluid system that pressurizeschamber 33 with air from the exterior of footwear 10 or a reservoirwithin footwear 10. As examples, chamber 33 may be utilized incombination with any of the fluid systems disclosed in U.S. Pat. No.7,210,249 to Passke, et al. and U.S. Pat. No. 7,409,779 to Dojan, et al.

Chamber Configuration

Chamber 33 is depicted individually in FIGS. 4-8D in an initialconfiguration that is suitable for footwear applications. Chamber 33 hasa contoured configuration, and when incorporated into footwear 10,chamber 33 corresponds with substantially all of footwear 10. When thefoot is located within upper 20, chamber 33 extends under the foot inorder to attenuate ground reaction forces that are generated when solestructure 30 is compressed between the foot and the ground duringvarious ambulatory activities, such as running and walking. In otherconfigurations, chamber 33 may have an alternate extent, such asextending under a forefoot area of the foot, or a heel area of the foot,for example. Additionally, although chamber 33 is depicted as beingexposed on both lateral side 14 and medial side 15 of footwear 10, insome configurations of footwear 10, a polymer foam material of midsole31 may form at least part of a sidewall of midsole 31.

The primary elements of chamber 33 are an outer barrier 40 and tensilestructures 50 a-50 d. Barrier 40 (a) forms an exterior of chamber 33,(b) defines an interior void that receives both a pressurized fluid andtensile structures 50 a-50 d, and (c) provides a durable sealed barrierfor retaining the pressurized fluid within chamber 33. The polymermaterial of barrier 40 includes (a) a first barrier portion 41 orientedtoward upper 20 that may form an upper portion of barrier 40, (b) anopposite second barrier portion 42 oriented toward outsole 32 that mayform a lower portion of barrier 40, and (c) a peripheral edge 43 thatextends around a periphery of chamber 33 and between barrier portions 41and 42.

As depicted in FIGS. 4-8D, tensile structures 50 a-50 d are locatedwithin the interior void and may be tensile members such as textiletensile members. In other configurations, tensile structures may includeelements that are not textile tensile members, such as any of the tetherelements disclosed in U.S. patent application Ser. No. 12/630,642 toPeyton and U.S. patent application Ser. No. 12/777,167 to Peyton. Insome configurations, tensile member 50 may be formed from, or be formedto include a foam tensile member such as any of the foam tensile membersdisclosed in U.S. Pat. No. 7,131,218 to Schindler, U.S. Pat. No.7,588,654 to Schindler et al., and U.S. Pat. No. 7,591,919 to Schindleret al.

Tensile structures 50 a-50 d may include upper tensile layers 51 a-51 d,opposite lower tensile layers 52 a-52 d, and pluralities of connectingmembers 53 a-53 d, respectively, that extend between tensile layers 51a-51 d and 52 a-52 d. Upper tensile layers 51 a-51 d are secured toinner surfaces of first barrier portion 41 and lower tensile layers 52a-52 d are secured to inner surfaces of second barrier portion 42.Connecting members 53 a-53 d may include yarns, fibers, or filamentsformed of a variety of materials, and may be positioned across lengthsand widths of tensile structures 52 a-52 d at relatively sparsedensities, relatively packed densities, or any other densities. Althoughdiscussed in greater detail below, either adhesive bonding orthermobonding may be utilized to secure tensile structures 50 a-50 d tobarrier 40. Tensile structures 50 a-50 d may be located in differentareas of chamber 33 and may have different heights.

A wide range of polymer materials may be utilized for barrier 40. Inselecting materials for barrier 40, engineering properties of thematerials (e.g., tensile strength, stretch properties, fatiguecharacteristics, dynamic modulus, and loss tangent) as well as theability of the materials to prevent the diffusion of the fluid containedby barrier 40 may be considered. When formed of thermoplastic urethane,for example, barrier 40 may have a thickness of approximately 1.0millimeter, but the thickness may range from less than 0.25 to more than2.0 millimeters, for example. In addition to thermoplastic urethane,examples of polymer materials that may be suitable for barrier 40include polyurethane, polyester, polyester polyurethane, and polyetherpolyurethane. Barrier 40 may also be formed from a material thatincludes alternating layers of thermoplastic polyurethane andethylene-vinyl alcohol copolymer, as disclosed in U.S. Pat. Nos.5,713,141 and 5,952,065 to Mitchell, et al. A variation upon thismaterial may also be utilized, wherein a center layer is formed ofethylene-vinyl alcohol copolymer, layers adjacent to the center layerare formed of thermoplastic polyurethane, and outer layers are formed ofa regrind material of thermoplastic polyurethane and ethylene-vinylalcohol copolymer. Another suitable material for barrier 40 is aflexible microlayer membrane that includes alternating layers of a gasbarrier material and an elastomeric material, as disclosed in U.S. Pat.Nos. 6,082,025 and 6,127,026 to Bonk, et al. Additional suitablematerials are disclosed in U.S. Pat. Nos. 4,183,156 and 4,219,945 toRudy. Further suitable materials include thermoplastic films containinga crystalline material, as disclosed in U.S. Pat. Nos. 4,936,029 and5,042,176 to Rudy, and polyurethane including a polyester polyol, asdisclosed in U.S. Pat. Nos. 6,013,340, 6,203,868, and 6,321,465 to Bonk,et al.

A variety of processes may be utilized to manufacture chamber 33. Ingeneral, the manufacturing processes involve (a) securing a pair ofpolymer sheets, which form barrier portions 41 and 42 as well asperipheral edge 43, to opposite sides of tensile structures 50 a-50 d(i.e., to tensile layers 51 a-51 d and 52 a-52 d) and (b) forming aperipheral bond 44 that joins a periphery of the polymer sheets and mayextend around peripheral edge 43. Peripheral bond 44 is depicted asbeing adjacent to the upper surface of chamber 33, but may be positionedbetween the upper and lower surfaces of chamber 33, or may be adjacentto the lower surface of chamber 33. The thermoforming process may also(a) locate tensile structures 50 a-50 d within chamber 33, and (b) bondtensile structures 50 a-50 d to each of barrier portions 41 and 42.Although substantially all of the thermoforming process may be performedwith a mold, as described in greater detail below, each of the variousparts or steps of the process may be performed separately in formingchamber 33. That is, a variety of other methods may be utilized to formchamber 33.

In order to facilitate bonding between tensile structures 50 a-50 d andbarrier 40, polymer supplemental layers may be applied to any of tensilelayers 51 a-51 d and 52 a-52 d. When heated, the supplemental layerssoften, melt, or otherwise begin to change state so that contact withbarrier portions 41 and 42 induces material from each of barrier 40 andthe supplemental layers to intermingle or otherwise join with eachother. Upon cooling, therefore, the supplemental layers are permanentlyjoined with barrier 40, thereby joining tensile structures 50 a-50 dwith barrier 40. In some configurations, thermoplastic threads or stripsmay be present within tensile layers 51 a-51 d and 52 a-52 d tofacilitate bonding with barrier 40, as disclosed in U.S. Pat. No.7,070,845 to Thomas, et al., or an adhesive may be utilized to securebarrier 40 to any of tensile structures 50 a-50 d.

Following the thermoforming process, or as part of the thermoformingprocess, a fluid may be injected into the interior void and pressurizedbetween zero and three-hundred-fifty kilopascals (i.e., approximatelyfifty-one pounds per square inch) or more. The pressurized fluid exertsan outward force upon barrier 40, which tends to separate barrierportions 41 and 42. Tensile structures 50 a-50 d, however, are securedto each of barrier portions 41 and 42 in order to impose an intendedshape upon chamber 33 when pressurized. More particularly, connectingmembers 53 a-53 d extending across the interior void are placed intension by the outward force of the pressurized fluid upon barrier 40,thereby preventing barrier 40 from expanding outward and causing chamber33 to retain an intended shape. Whereas peripheral bond 44 joins thepolymer sheets to form a seal that prevents the fluid from escaping,tensile structures 50 a-50 d prevent barrier 40 from expanding outwardor otherwise distending due to the pressure of the fluid. That is,tensile structures 50 a-50 d effectively limit the expansion of chamber33 to retain an intended shape of barrier portions 41 and 42.

The lengths of connecting members within each plurality of connectingmembers 53 a-53 d are substantially constant throughout tensilestructures 50 a-50 d, which imparts the parallel configuration to eachof tensile layers 51 a-51 d and 52 a-52 d. In some configurations,however, the lengths of connecting members within at least one pluralityof connecting members 53 a-53 d may vary to impart a contouredconfiguration to chamber 33. For example, chamber 33 may taper or mayform a depression due to differences in the lengths of connectingmembers within each plurality of connecting members 53 a-53 d. Examplesof contoured tensile structures are disclosed in U.S. patent applicationSer. No. 12/123,612 to Dua and Ser. No. 12/123,646 to Rapaport, et al.Additionally, tensile structures 50 a-50 d may include tensile memberssuch as textile tensile members. That is, part of at least one oftensile structures 50 a-50 d may be formed of a textile tensile member.Textile tensile members may be cut or formed from a larger element of aspacer textile. Alternately, each of tensile elements 51 a-51 d and 52a-52 d may be formed to have a variety of configurations through, forexample, a flat-knitting process, as in U.S. patent application Ser. No.12/123,612 to Dua.

Suitably configured, tensile structures 50 a-50 d may have any of arange of configurations, including the range of configurations disclosedin U.S. patent application Ser. No. 12/123,612 to Dua, U.S. patentapplication Ser. No. 12/123,646 to Rapaport, et al., and U.S. patentapplication Ser. No. 12/630,642 to Peyton. In some configurations,chamber 33 may incorporate a valve or other structure that permits theindividual to adjust the pressure of the fluid. Additionally, chamber 33may be incorporated into a fluid system, similar to a fluid systemdisclosed in U.S. Pat. No. 7,409,779 to Dojan, et al., that varies thepressure within barrier 40 depending upon, for example, the runningstyle or weight of the wearer.

As depicted in FIGS. 4-8D, chamber 33, as well as tensile structures 50a-50 d within chamber 33, extend substantially throughout footwear 10.Tensile structures 50 a-50 d are located in different areas of chamber33, or in different areas of barrier 40 that forms an exterior ofchamber 33 and defines an interior void within chamber 33. Tensilestructure 50 a is located in a first area of chamber 33, or in a firstarea of barrier 40 and within the interior void. Tensile structure 50 bis located in a second area of chamber 33, or in a second area ofbarrier 40 and within the interior void. Tensile structure 50 b issubstantially in heel region 13 of footwear 10, and tensile structure 50a is rearward of tensile structure 50 b. Tensile structure 50 c islocated in a third area of chamber 33, or in a third area of barrier 40and within the interior void. Tensile structure 50 c is at leastpartially located in midfoot region 12 of footwear 10. Tensile structure50 c includes a lateral segment 55 a and a medial segment 55 b ofsimilar extent. Finally, tensile structure 50 d is located in a fourtharea of chamber 33, or in a fourth area of barrier 40 and within theinterior void. Tensile structure 50 d is located forward of tensilestructure 50 c and at least partially located between lateral segment 55a and medial segment 55 b. The first area, second area, third area, andfourth area are in fluid communication with each other.

Additionally, each of tensile structures 50 a-50 d may have a differentheight than the other tensile structures 50 a-50 d. Tensile structure 50a has a height less than tensile structure 50 b. Tensile structure 50 bhas a height greater than tensile structure 50 c. Finally, tensilestructure 50 c has a height greater than tensile structure 50 d. Inturn, the relative locations and differences of height of tensilestructure 50 a-50 d impart a contoured configuration to footwear 10. Asdepicted in FIGS. 4-8D, the relative locations and differences of heightof tensile structures 50 a-50 d impart contours including a heel beveland a forefoot pocket.

As depicted in FIGS. 4-8D, tensile structures 50 a-50 d are adjacent toeach other. That is, tensile structures 50 a-50 d are positioned next toeach other such that at least part of each tensile structure 50 a-50 deither directly contacts or is minimally spaced from one or more of theother tensile structures 50 a-50 d. However, where one tensile 50 a-50 dstructure has a height greater than another nearby tensile structure 50a-50 d, a portion of the chamber 33 in the area of the tensile structurewith the greater height may have a shape imposed by the nearby tensilestructure with the lesser height rather than a shape imposed by thetensile structure with the greater height. Accordingly, in someconfigurations, tensile structures may be spaced apart, and a portion ofchamber 33 in the area in which the tensile structures are spaced apartmay still have a shape imposed by the nearby tensile structure with thelesser height.

In some configurations, one or more portions of the outer barrier may beformed to include a molded height gradient. A molded height gradientlocated between two areas incorporating tensile structures of differentheights may concentrate an imparted height difference between the twoareas of the inflated chamber on one barrier portion of the chamber. Invarious configurations, barrier portion 41 or 42 may be molded orotherwise formed to include a molded height gradient 58 at leastpartially proximal to at least two tensile structures, such as at alocation between tensile structures. For example, as depicted in FIGS.4-8D, second barrier portion 42 is formed to include molded heightgradient 58 located proximal to and between tensile structures 50 b and50 c. In turn, a difference in height between the area of chamber 33incorporating tensile structure 50 b and the area of chamber 33incorporating tensile structure 50 c may be greater on second barrierportion 42 than on first barrier portion 41. As a result, molded heightgradient 58 may concentrate a change in extension outward from chamber33 at a lower surface of chamber 33 between the different areas ofchamber 33 incorporating tensile structures 50 b and 50 c.

Although depicted in FIGS. 4-8D as including four tensile structures 50a-50 d, various configurations of chambers 33 may include fewer tensilestructures. In some configurations, chamber 33 may incorporate at leasta first tensile structure and a second tensile structure. The tensilestructures of chamber 33 may be located in different areas of chamber33, or in different areas of barrier 40 and within the interior void,and may have different heights. For example, chamber 33 may incorporatea first tensile structure located in a first area and having a firstheight, and may incorporate a second tensile structure located in asecond area and having a second height, the first height being greaterthan the second height. In some configurations, the first tensilestructure and the second tensile structure may each be part of a singletensile structure that is contoured, tapered, or otherwise formed tohave more than one height, where the first tensile structure is at leastpartially separated from the second tensile structure by at least oneinterior bond. That is, some part of the first tensile structure andsome part of the second tensile structure may be at least partiallyseparated by at least one interior bond.

Alternatively, the first tensile structure may have a first height at afirst part near the second tensile structure, and the second tensilestructure may have a second height at a second part near the firsttensile structure, the second height being greater than the firstheight. That is, while both the first and second tensile structures mayhave a substantially flat configuration, either or both of the firsttensile structure and the second tensile structure may be contoured, ormay otherwise have more than one height, and a height of the secondtensile structure at least at one point near the first tensile structuremay be greater than a height of the first tensile structure at least atone point near the second tensile structure.

Chamber 33 may also be substantially free of internal bonds, i.e., bondsspaced inward from a peripheral edge of chamber 33. Accordingly, thefirst area of chamber 33 at which the first tensile structure is locatedand the second area of chamber 33 at which the second tensile structureis located may be in fluid communication. For example, chamber 33 may besubstantially free of interior bonds between a first part of the firsttensile structure near the second tensile structure and a second part ofthe second tensile structure near the first tensile structure.

Alternatively, chamber 33 may include at least one interior bond betweena third part of the first tensile structure near the second tensilestructure and a fourth part of the second tensile structure near thefirst tensile structure. That is, chamber 33 may be substantially freeof interior bonds at one area between a first tensile structure andsecond tensile structure, but chamber 33 may include one or moreinternal bonds at a second area between the first tensile structure andthe second tensile structure.

Similarly, although depicted in FIGS. 4-8D as including four tensilestructures 50 a-50 d, various configurations of chambers 33 incorporatedinto articles of footwear may include fewer tensile structures, and thelocations and relative heights of those tensile structures withinchamber 33 may vary as well. In some configurations of footwear, chamber33 may incorporate a first tensile structure having a first height at afirst part near the second tensile structure and a second tensilestructure having a second height at a second part near the first tensilestructure, the second height being greater than the first height.

In such configurations, the first tensile structure may be at leastpartially located in a heel region of the footwear, and the secondtensile structure may be at least partially located in a midfoot regionof the footwear.

Alternatively, in such configurations, the second tensile structure maybe located in at least a heel region of the footwear, and the firsttensile structure may be located rearward of the second tensilestructure. Such configurations may also include a third tensilestructure located within the outer barrier having a third height at athird part near the second tensile structure, the third height beingless than the second height, and the third tensile structure beinglocated forward of the second tensile structure.

As a further alternative, in such configurations, the first tensilestructure may be located in at least a midfoot region of the footwear,and the second tensile structure may be located forward of the firsttensile structure. The first tensile structure of such configurationsmay also include a lateral segment and a medial segment, and the secondtensile structure may be at least partially located between the lateralsegment and the medial segment.

In other configurations of footwear, chamber 33 may incorporate a firsttensile structure having a first height in a first area and a secondtensile structure having a second height in a second area, the secondheight being greater than the first height. In such a configuration, thesecond tensile structure may be located in at least a heel region of thefootwear, and the first tensile structure may be located rearward of thesecond tensile structure, as part of a heel bevel structure of thefootwear.

In some configurations of footwear, chamber 33 may incorporate a firsttensile structure having a first height in a first area and a secondtensile structure having a second height in a second area, the secondheight being less than the first height. In such a configuration, thefirst tensile structure may be located in at least a midfoot region ofthe footwear, and the second tensile structure may be located forward ofthe first tensile structure.

In other configurations of footwear, chamber 33 may incorporate a firsttensile structure located within the outer barrier in a first area ofchamber 33, a second tensile structure located within the outer barrierin a second area of chamber 33, and a third tensile structure locatedwithin the outer barrier in a third area of chamber 33. In suchconfigurations, the first area may be in a rear-most region of thechamber and may have a first height, the second area of the chamber maybe between the rear-most region of the chamber and a fore-most region ofthe chamber and may have a second height greater than the first height,and the third area of the chamber may be in a fore-most region of thechamber and may have a third height less than the second height. Thesecond tensile structure in such configurations may also include alateral segment and a medial segment, and the third tensile structuremay be at least partially located between the lateral segment and themedial segment.

In other words, in various configurations, two or more tensilestructures having various heights may be incorporated into differentareas of a chamber 33. One or more tensile structures may be located ina heel region, or in a midfoot region, or in a forefoot region ofchamber 33, and one or more other tensile structures may be located indifferent areas of chamber 33. Additionally, tensile structuresincorporated into chamber 33 may have various shapes. For example, invarious configurations, a tensile structure may have lateral or medialsegments in which one or more medial or lateral portions of the tensilestructure extend further forward, further rearward, or both, relative tomore central portions of the tensile structure, i.e., portions of thetensile structure between the medial and lateral portions of the tensilestructure.

The various configurations of chamber 33 described above may beincorporated into an article of footwear or any of a variety of otherproducts, such as apparel, athletic equipment, cushions, and othercompressible structures. By incorporating a plurality of tensilestructures having different heights into different areas of chamber 33,one or more properties of chamber 33 may be altered, such as aflexibility, stiffness, rigidity, tensile response, compressibility, orforce attenuation property of chamber 33. Additionally, a taper orcontour may be imparted to chamber 33 without use of a tensile structurethat is itself tapered or contoured.

Manufacturing Process

Although a variety of manufacturing processes may be utilized to formchamber 33, an example of a suitable thermoforming process will now bediscussed. With reference to FIG. 9, a mold 60 that may be utilized inthe thermoforming process is depicted as including an upper mold portion61 and a lower mold portion 62. Mold 60 is utilized to form chamber 33from a pair of polymer sheets that are molded and bonded to definebarrier portions 41 and 42 as well as peripheral edge 43, and thethermoforming process secures tensile structures 50 a-50 d withinbarrier 40. More particularly, mold 60 (a) imparts shape to one of thepolymer sheets in order to form first barrier portion 41, (b) impartsshape to the other of the polymer sheets in order to form second barrierportion 42, (c) imparts shape to the polymer sheets in order to formperipheral edge 43 and to form peripheral bond 44 to join a periphery ofthe polymer sheets, (d) locates tensile structures 50 a-50 d withinchamber 33, and (e) bonds tensile structures 50 a-50 d to each ofbarrier portions 41 and 42.

In this example manufacturing process, each of tensile structures 50a-50 d may be a textile tensile member. In other manufacturingprocesses, each of tensile structures 50 a-50 d may include one or moretextile tensile members, and may also include one or more elements thatare not textile tensile members, such as tether elements.

In preparation for the manufacturing process, various elements formingchamber 33 may be obtained and organized. For example, an upper polymerlayer 71 and a lower polymer layer 72, which form barrier 40, may be cutto a desired shape. Tensile structures 50 a-50 d are in a compressedstate at this stage of the manufacturing process, wherein textile layers51 a-51 d and 52 a-52 d lie adjacent to each other and connectingmembers 53 a-53 d are in a collapsed state. Upon completion of themanufacturing process, when chamber 33 is pressurized, tensilestructures 50 a-50 d are placed in tension, which spaces textile layers51 a-51 d and 52 a-52 d from each other and induces connecting members53 a-53 d to straighten.

In manufacturing chamber 33, one or more of upper polymer layer 71,lower polymer layer 72, and tensile structures 50 a-50 d are heated to atemperature that facilitates bonding between the components. Dependingupon the specific materials utilized for tensile structures 50 a-50 dand polymer layers 71 and 72, which form barrier 40, suitabletemperatures may range from 120 to 200 degrees Celsius (248 to 392degrees Fahrenheit) or more. Various radiant heaters or other devicesmay be utilized to heat the components of chamber 33. In somemanufacturing processes, mold 60 may be heated such that contact betweenmold 60 and the components of chamber 33 raises the temperature of thecomponents to a level that facilitates bonding.

Following heating, the components of chamber 33 are located between moldportions 61 and 62, as depicted in FIGS. 10A and 11A. In order toproperly position the components, a shuttle frame or other device may beutilized. Once positioned, mold portions 61 and 62 translate toward eachother and begin to close upon the components such that (a) upper moldportion 61 contacts upper polymer layer 71, (b) lower ridge 64 of lowermold portion 62 contacts lower polymer layer 72, and (c) polymer layers71 and 72 begin bending around tensile structures 50 a-50 d so as toextend into a cavity within mold 60, as depicted in FIGS. 10B and 11B.The components are thus located relative to mold 60 and initial shapingand positioning has occurred.

At the stage depicted in FIGS. 10B and 11B, air may be partiallyevacuated from the area around polymer layers 71 and 72 through variousvacuum ports in mold portions 61 and 62. The purpose of evacuating theair is to draw polymer layers 71 and 72 into contact with the variouscontours of mold 60. This ensures that polymer layers 71 and 72 areproperly shaped in accordance with the contours of mold 60. Note thatpolymer layers 71 and 72 may stretch in order to extend around tensilemembers 50 a-50 d and into mold 60. In comparison with the thickness ofbarrier 40 in chamber 33, polymer layers 71 and 72 may exhibit greateroriginal thickness. This difference between the original thicknesses ofpolymer layers 71 and 72 and the resulting thickness of barrier 40 mayoccur as a result of the stretching taking place at this stage of thethermoforming process.

A movable insert 65 that is supported by various springs 66 may depressto place a specific degree of pressure upon the components, therebybonding polymer layers 71 and 72 to opposite surfaces of tensilestructures 50 a-50 d. Movable insert 65 includes a peripheralindentation 67 that forms peripheral edge 43 from lower polymer layer72. Movable insert 65 may also include one or more height gradients 68.Before the inflation of chamber 33, height gradients 68 may impart aheight difference to a surface of chamber 33 in one or more differentareas of chamber 33. In turn, after the inflation of chamber 33, suchheight differences may concentrate at that surface of chamber 33 achange in height between different areas of chamber 33. In someconfigurations of mold 60, movable insert 65 and springs 66 may beabsent, and features such as peripheral indentation 67 and heightgradients 68 may instead be incorporated into lower mold portion 62.Furthermore, in some configurations of mold 60, portions of featuressuch as peripheral indentation 67 and height gradients 68 may beincorporated into upper mold portion 61 as well as, or instead of, beingincorporated into movable insert 65 or lower mold portion 62.

As mold 60 closes further, upper mold portion 61 and ridge 64 bond upperpolymer layer 71 to lower polymer layer 72, as depicted in FIGS. 100 and11C, thereby forming peripheral bond 44. Furthermore, portions of ridge64 that extend away from tensile structures 50 a-50 d form a bondbetween other areas of polymer layers 71 and 72, contributing to theformation of inflation conduit 73.

In order to provide a second means for drawing polymer layers 71 and 72into contact with the various contours of mold 60, the area betweenpolymer layers 71 and 72 and proximal to tensile structures 50 a-50 dmay be pressurized. During a preparatory stage of this method, aninjection needle may be located between polymer layers 71 and 72, andthe injection needle may be located such that ridge 64 envelops theinjection needle when mold 60 closes. A gas may then be ejected from theinjection needle such that polymer layers 71 and 72 engage ridge 64.Inflation conduit 73 may thereby be formed (see FIG. 10D) betweenpolymer layers 71 and 72. The gas may then pass through inflationconduit 73, thereby entering and pressurizing the area proximal totensile structures 50 a-50 d and between polymer layers 71 and 72. Incombination with the vacuum, the internal pressure ensures that polymerlayers 71 and 72 contact the various surfaces of mold 60.

As discussed above, a supplemental layer of a polymer material orthermoplastic threads may be applied to textile layers 51 a-51 d and 52a-52 d in order to facilitate bonding between tensile structures 50 a-50d and barrier 40. The pressure exerted upon the components by movableinsert 65 ensures that the supplemental layer or thermoplastic threadsform a bond with polymer layers 71 and 72.

When bonding is complete, mold 60 is opened and chamber 33 and excessportions of polymer layers 71 and 72 are removed and permitted to cool,as depicted in FIGS. 10D and 11D. A fluid may be injected into chamber33 through the inflation needle and inflation conduit 73. Upon exitingmold 60, tensile structures 50 a-50 d remain in the compressedconfiguration. When chamber 33 is pressurized, however, the fluid placesan outward force upon barrier 40, which tends to separate barrierportions 41 and 42, thereby placing tensile structures 50 a-50 d intension and imparting a contoured configuration to chamber 33. Inaddition, a sealing process is utilized to seal inflation conduit 73adjacent to chamber 33 after pressurization. The excess portions ofpolymer layers 71 and 72 are then removed, thereby completing themanufacture of chamber 33, as depicted in FIGS. 10E and 11E. As analternative, the order of inflation and removal of excess material maybe reversed. As a final step in the process, chamber 33 may be testedand then incorporated into midsole 31 of footwear 10.

Further Configurations

As depicted in FIGS. 4-8D, each of tensile structures 50 a-50 d extendsthroughout one of a set of different areas of chamber 33. In otherwords, portions of tensile structures 50 a-50 d located inward fromtheir peripheries are not interrupted by interior bonds. However, inother configurations, interior bonds may extend through gaps such asapertures in tensile structures of chamber 33. For example, as depictedin FIG. 12A, Interior bonds 56 a-56 c extend through gaps 57 a-57 c intensile structures 50 b-50 d to join first barrier layer 41 to secondbarrier layer 42.

As depicted in FIGS. 4-8D, tensile structures 50 a-50 d are adjacent toeach other, and chamber 33 is substantially free of interior bondsbetween tensile structures 50 a-50 d. In other configurations, interiorbonds between tensile structures may extend through gaps in the tensilestructures, such as apertures or recesses in the tensile structures. Forexample, as depicted in FIG. 12B, interior bonds 56 a extend inward fromperipheral bond 44 through gaps 57 a in tensile structure 50 a to aninterior of chamber 33. Tensile structure 50 a is formed to have a firstheight at a first part and a second height at a second part, the secondheight being greater than the first height, and interior bonds 56 aseparate the first part from the second part. In addition, interiorbonds 56 b extend through gaps 57 b having convex shapes andcooperatively formed by recesses in tensile structure 50 a and tensilestructure 50 b, and interior bonds 56 c extend through gaps 57 c havingnon-convex shapes and cooperatively formed by recesses in tensilestructure 50 b and tensile structure 50 c.

As depicted in FIGS. 4-8D, each of tensile structures 50 a-50 d has asubstantially flat configuration and incorporates connecting members 53a-53 d of relatively uniform heights. In other configurations, thelengths of any of connecting members 53 a-53 d may vary, or one or moretensile structures may be contoured, tapered, or otherwise formed tohave more than one height. For example, as depicted in FIGS. 12C and13A, tensile structure 50 b is contoured to have a greater height inheel region 13 than in midfoot region 12 and forefoot region 11.

As depicted in FIGS. 4-8D, tensile structures 50 a-50 d are positionednext to each other such that portions of each tensile structure 50 a-50d either directly contacts or is minimally spaced from other tensilestructures 50 a-50 d. In other configurations, a gap or space may atleast partially separate tensile structures. For example, as depicted inFIGS. 12D and 13B, gap 57 a separates tensile structure 50 a fromtensile structure 50 b, gap 57 b separates tensile structure 50 b fromtensile structure 50 c, and gap 57 c separates tensile structure 50 cfrom tensile structure 50 d.

As depicted in FIGS. 4-8D, tensile structure 50 c includes lateralsegment 55 a and medial segment 55 b of similar extent. In otherconfigurations, tensile structures located in other areas of chamber 33may have lateral segments or medial segments, and may have lateral andmedial segments of differing extent. For example, as depicted in FIG.12E, tensile structure 50 b has lateral segments and medial segmentsextending both toward forefoot region 11 of chamber 33 and toward arear-most region of chamber 33. In addition, lateral segment 55 a andmedial segment 55 b of tensile structure 50 c have differing extent.

As depicted in FIGS. 4-8D, chamber 33, as well as tensile structures 50a-50 d within chamber 33, extend substantially throughout footwear 10.In other configurations, chamber 33 and tensile structures withinchamber 33 may extend through any areas or regions of footwear 10. Forexample, as depicted in FIG. 12F, chamber 33 and tensile structures 50 aand 50 b within chamber 33 are configured to extend throughout heelregion 13 of footwear 10. In such configurations, tensile structure 50 bmay be configured to extend throughout additional areas or regions ofchamber 33, such as midfoot region 12 and forefoot region 11, up to thefull length of chamber 33. Alternatively, as depicted in FIG. 12G,chamber 33 and tensile structures 50 c and 50 d within chamber 33 areconfigured to extend throughout midfoot region 12 and forefoot region 11of footwear 10. In such configurations, tensile structure 12 c may beconfigured to extend throughout additional areas or regions of chamber33, such as heel region 13, up to the full length of chamber 33. Inother configurations, chamber 33 and tensile structures within chamber33 may extend throughout lateral side 14 of footwear 10, medial side 15of footwear 10, or any areas or regions of sides 14 and 15 of footwear10.

Additionally, one or more regions of chamber 33 may be formed or shapedto accommodate additional portions of article of footwear 10. Forexample, in embodiments in which chamber 33 corresponds withsubstantially all of footwear 10, a cavity might be formed in midfootregion 12 of chamber 33 to accommodate an electrical or electronicdevice.

As depicted in FIGS. 4-8D, tensile structures 50 a-50 d extend in asubstantially contiguous manner throughout a central portion of chamber33, the central portion being spaced inward by a small amount fromperipheral edge 43 and extending throughout most of chamber 33. In otherwords, tensile structures 50 a-50 d substantially extend throughout mostof the interior void within chamber 33. In other configurations, tensilestructures may extend throughout less than most of the interior voidwithin chamber 33. For example, as depicted in FIG. 12H, tensilestructures 50 a and 50 b extend throughout portions of heel region 13,midfoot region 12, and forefoot region 11 of chamber 33, and chamber 33has been formed to include interior bonds 56 a and 56 b in portions ofheel region 13 and forefoot region 11 through which tensile structures50 a and 50 b do not extend.

As depicted in FIGS. 4-8D, second barrier portion 42 of chamber 33 isformed to include molded height gradient 58 between an area of chamber33 incorporating tensile structure 50 b and an area of chamber 33incorporating tensile structure 50 c. In other configurations, chamber33 may be formed to include a molded height gradient between anydifferent areas of chamber 33. For example, as depicted in FIG. 13C,second barrier portion 42 does not include a molded height gradientbetween areas of chamber 33 incorporating tensile structures 50 b and 50c. Instead, second barrier portion 42 includes molded height gradients58 between areas of chamber 33 incorporating tensile structures 50 a and50 b, and between areas of chamber 33 incorporating tensile structures50 c and 50 d.

As depicted in FIGS. 4-8D, tensile structures 50 a-50 d of differentheights may be textile tensile members of different heights. In otherconfigurations, tensile structures may be formed of stacked tensilemembers. Additionally, different stacked tensile structures havingdifferent heights and incorporated into different areas of chamber 33may be formed to incorporate different portions of the same tensilemember. For example, as depicted in FIG. 13D, each of tensile structures50 a-50 d includes as part of its structure a textile tensile memberextending across and through all of the different areas of chamber 33associated with tensile structures 50 a-50 d, and each of tensilestructures 50 a-50 c additionally includes as part of its structureanother textile tensile member. In some configurations, tensilestructures may include textile tensile members stacked and non-textiletensile members. Accordingly, stacked tensile structures may generallytake the form of any stacked configuration, such as the stackedconfigurations disclosed in U.S. patent application Ser. No. 12/938,175,filed 2 Nov. 2010 and entitled “Fluid-Filled Chamber With A StackedTensile Member,” and may include elements that are not textile tensilemembers, such as any of the tether element disclosed in U.S. patentapplication Ser. No. 12/630,642 to Peyton and U.S. patent applicationSer. No. 12/777,167 to Peyton.

As depicted in FIGS. 4-8D, the relative locations and differences ofheight of tensile structures 50 a-50 d impart contours including a heelbevel and a forefoot pocket. In other configurations, the relativelocations and differences of height of tensile structures within chamber33 may impart contours of other features. For example, as depicted inFIG. 13E, the relative locations and differences of height of tensilestructures 50 a-50 e impart a tapered configuration to chamber 33. Inanother example, as depicted in FIG. 14, the relative locations anddifferences of height of tensile structures 50 a and 50 b impart amedio-lateral taper to chamber 33, which may serve as a medially-locatedarch support. In a further example, as depicted in FIG. 15, the relativelocations and differences of height of tensile structures 50 a and 50 bimpart a heel-cup configuration to chamber 33.

As depicted in FIGS. 4-8C, chamber 33 is suitable for use in footwear.In other configurations, chamber 33 may be suitable for use in otherproducts, such as apparel, athletic equipment, cushions, and othercompressible structures. For example, as depicted in FIG. 16B, chamber233 may be incorporated into a headrest 200. In another example, asdepicted in FIG. 16B, chamber 333 may be incorporated into a seatcushion 300.

Tensile structures of different heights may be included in otherfluid-filled chambers as well. For example, as depicted in FIGS. 17 and18, tensile members 450 a-450 e have been included in fluid-filledchamber 433 along with other elements. Chamber 433 includes indentedareas 446 and bonded regions 448. Chamber 433 also includes tensilemembers 450 a-450 e, whose heights may differ, which may in turn imparta contour to chamber 433. Additionally, chamber 433 includes a windowportion having both first window areas 457 a-457 d and opposite secondwindow areas 458 a-458 d, which may have different extents of outwardprotrusion, including a variation between a lateral side and a medialside of chamber 433.

The invention is disclosed above and in the accompanying figures withreference to a variety of configurations. The purpose served by thedisclosure, however, is to provide an example of the various featuresand concepts related to the invention, not to limit the scope of theinvention. One skilled in the relevant art will recognize that numerousvariations and modifications may be made to the configurations describedabove without departing from the scope of the present invention, asdefined by the appended claims.

The invention claimed is:
 1. A fluid-filled chamber for a solestructure, the fluid-filled chamber comprising: an outer barrierdefining an interior void and extending from a forefoot region of thesole structure to a heel region of the sole structure along alongitudinal axis; a first tensile structure disposed within theinterior void, bonded to the outer barrier, and including a firstheight; and a second tensile structure disposed within the interiorvoid, bonded to the outer barrier within a midfoot region of the solestructure, extending form the midfoot region into the forefoot region,and including a second height different than the first height, thesecond tensile structure including (i) a first portion extendingcontinuously across a width of the outer barrier at the second heightfrom a medial side of the outer barrier to a lateral side of the outerbarrier, (ii) a second portion extending from the first portion andalong the medial side of the outer barrier within the forefoot region,and (iii) a third portion extending from the first portion and along thelateral side of the outer barrier within the forefoot region.
 2. Thefluid-filled chamber of claim 1, wherein the second height is greaterthan the first height.
 3. The fluid-filled chamber of claim 1, whereinthe first tensile structure extends between the second portion of thesecond tensile structure and the third portion of the second tensilestructure.
 4. The fluid-filled chamber of claim 1, further comprising athird tensile structure disposed within the interior void, bonded to theouter barrier, and including a third height that is greater than thefirst height and the second height.
 5. The fluid-filled chamber of claim4, wherein the third tensile structure extends from the medial side ofthe outer barrier to the lateral side of the outer barrier.
 6. Thefluid-filled chamber of claim 4, further comprising a fourth tensilestructure disposed within the interior void, bonded to the outerbarrier, and including a fourth height that is less than the thirdheight.
 7. The fluid-filled chamber of claim 6, wherein the thirdtensile structure is disposed between the fourth tensile structure andthe forefoot region.
 8. The fluid-filled chamber of claim 6, wherein thefluid-filled chamber includes an outer surface having a variablethickness extending in a direction along the longitudinal axis.
 9. Afluid-filled chamber for a sole structure, the fluid-filled chambercomprising: an outer barrier defining an interior void and extendingfrom a forefoot region of the sole structure to a heel region of thesole structure along a longitudinal axis; a first tensile structuredisposed within the interior void, bonded to the outer barrier,including a first height, and extending continuously at the first heightfrom a medial side of the outer barrier to a lateral side of the outerbarrier; and a second tensile structure disposed within the interiorvoid, bonded to the outer barrier, extending from a midfoot region ofthe sole structure into the forefoot region, including a second heightdifferent than the first height, and extending continuously at thesecond height from the medial side of the outer barrier to the lateralside of the outer barrier, the second tensile structure including afirst portion extending along the medial side of the outer barrierwithin the forefoot region and a second portion extending along thelateral side of the outer barrier within the forefoot region.
 10. Thefluid-filled chamber of claim 9, wherein the second height is greaterthan the first height.
 11. The fluid-filled chamber of claim 9, whereinthe first tensile structure extends between the first portion of thesecond tensile structure and the second portion of the second tensilestructure.
 12. The fluid-filled chamber of claim 9, further comprising athird tensile structure disposed within the interior void, bonded to theouter barrier, and including a third height that is greater than thefirst height and the second height.
 13. The fluid-filled chamber ofclaim 12, wherein the third tensile structure extends from the medialside of the outer barrier to the lateral side of the outer barrier. 14.The fluid-filled chamber of claim 12, further comprising a fourthtensile structure disposed within the interior void, bonded to the outerbarrier, and including a fourth height that is less than the thirdheight.
 15. The fluid-filled chamber of claim 14, wherein the thirdtensile structure is disposed between the fourth tensile structure andthe forefoot region.
 16. The fluid-filled chamber of claim 14, whereinthe fluid-filled chamber includes an outer surface having a variablethickness extending in a direction along the longitudinal axis.